How BIG SKY PACKAGING Powered the Launch of SunsolveMD’s Clinical-Grade Suncare Line?

Have you ever felt that sun care brands often overlook the functionality of their packaging? In a world where SPF is becoming a daily essential, packaging needs to do more than just look good—it must deliver on ease, efficiency, and sustainability.

SunsolveMD, a forward-thinking, physician-founded startup under the SolveMD umbrella, has done just that. Headquartered in the UK, SunsolveMD entered the market with a bold proposition: deliver high-performance mineral-based SPF 50 formulas infused with active skincare ingredients—niacinamide, ceramides, marine phytoplankton, and zinc oxide (ZnO+)—in packaging that reflects their science-backed, eco-conscious mission.

As the brand focused on formulation development, clinical positioning, and building an elevated consumer experience, SunsolveMD turned to BIG SKY PACKAGING to execute on one of the most critical elements of their launch—the packaging.

A Strategic Partnership from Concept to Completion

BIG SKY PACKAGING served as SunsolveMD’s dedicated packaging partner, providing end-to-end support across component sourcing, customization, production oversight, and logistics. More than a vendor, BIG SKY PACKAGING became an integrated extension of the SunsolveMD team, ensuring that every detail—from tactile functionality to visual appeal—aligned with the brand’s elevated standards and sustainability values.

With a clear brief and ambitious goals, BIG SKY PACKAGING set out to design and deliver a custom packaging solution that combined clinical minimalism, modern luxury, and real-world performance—all within a startup’s go-to-market timeline.

Project Objectives

• Deliver functional, premium, and eco-conscious skincare packaging solutions for SunsolveMD’s debut SKUs.
• Align component aesthetics with the brand’s minimalist and clinical identity.
• Support formulation compatibility and filling line performance.
• Ensure speed to market through precise coordination and on-time delivery.
• Provide scalability for future growth and SKU expansion.

Scope of Work

The scope of services provided by BIG SKY PACKAGING was comprehensive, covering every stage of the packaging lifecycle:

Component Concept, Cost & Material Evaluation

SunsolveMD needed a range of packaging solutions that would not only house their science-rich SPF formulations but also elevate the unboxing experience. BIG SKY PACKAGING led the initial evaluation of packaging formats—bottles, pumps, applicators, and closures—balancing premium aesthetics, user-friendly function, cost-efficiency, and sustainability.

Working closely with SunsolveMD, the team selected materials that aligned with the brand’s TerraCycle partnership and overall clean beauty positioning.

Customization & Prototyping

To achieve SunsolveMD’s distinct clinical-luxury aesthetic, BIG SKY PACKAGING customized existing stock components—modifying form, finish, and ergonomics to elevate the final product. Prototypes were delivered to validate visual appeal, in-hand experience, and mechanical functionality prior to full production.

This step was essential in ensuring each component resonated with the brand’s target consumer—discerning, skin-conscious individuals looking for both efficacy and elegance.

Formulation Compatibility & Technical Collaboration

Given the SPF formulation’s inclusion of zinc oxide and other active ingredients, compatibility and stability were paramount. BIG SKY PACKAGING provided packaging components to SunsolveMD’s team to undergo rigorous compatibility testing.

Real-time feedback and insight were provided throughout the process, with BIG SKY PACKAGING engaging directly with SunsolveMD’s team. From torque tolerances to fill volume requirements and headspace considerations, BIG SKY PACKAGING played a hands-on role in optimizing each element for flawless production.

Color Matching & Final Component Selection

SunsolveMD’s minimalist branding called for a precisely curated color palette and clinical consistency across all SKUs. BIG SKY PACKAGING guided the brand through detailed color-matching processes and finalized production-ready specifications to ensure brand cohesion.

From soft-touch finishes to exacting tones and textures, every element of the packaging contributed to the brand’s clean, elevated visual language.

Production Oversight & Quality Assurance

BIG SKY PACKAGING managed the full production timeline, vendor communications, and AQL (Acceptable Quality Limit) QC/QA protocols. Throughout the process, the team ensured consistency in execution, tracked quality metrics, and delivered component QC inspection documentation for full transparency.

Logistics, Shipping & Forecasting

With a high-stakes launch on the horizon, timeliness was critical. BIG SKY PACKAGING coordinated international air shipping to guarantee on-time delivery of all components across SKUs. They also provided production forecasting guidance, enabling SunsolveMD to scale inventory and maintain continuity across all sales channels.

Real-Time Technical Support & Value-Added Solutions

What set BIG SKY PACKAGING apart was not just their technical expertise, but their responsiveness and collaboration. Throughout the project, they remained engaged at every touchpoint, helping the SunsolveMD team address and resolve real-world challenges.

Key areas of support included:

• Troubleshooting fill line performance issues.
• Ensuring packaging and formulation compatibility.
• Rapid adaptation to changes in fill specs or component requirements.
• Post-fill insights and best practices for scaling production.

This streamlined, single-point-of-contact approach eliminated common roadblocks and allowed SunsolveMD to stay focused on growing the brand.

Results That Speak Volumes

Metric – Packaging Delivery Timeliness

Result  – 100% on-time delivery for launch

Metric – SKU Launch Coverage

Result  – 100% of initial SKUs supported with customized components

Metric –  Technical Issues Post-Fill

Result  –  Challenges addressed and resolved at each stage

Metric –  Ongoing Collaboration

Result –  Continued engagement for new SKUs and sampling initiatives

Looking to the Future

With a successful initial launch under their belt, SunsolveMD continues to work with BIG SKY PACKAGING on:

• New Product Extensions: Evaluating and executing packaging for upcoming SPF and skincare SKUs.
• Sample Program Development: Engineering cost-effective, on-brand sample packaging formats for trial and acquisition.
• Sustainability Enhancements: Exploring new materials and upgrades to further reduce environmental impact without compromising quality or brand feel.

Final Words: Packaging as a Strategic Growth Driver

“Building a brand within the biotech and clinical skincare space requires not just formulation integrity, but absolute precision across packaging, stability, and delivery systems. Partnering with technical teams who understand how to execute at that level — while respecting the nuance of the brand vision — is essential.”

 Portia Dieguez, Chief Strategy Officer, SunsolveMD

By functioning as a true partner, not just a vendor, BIG SKY PACKAGING reduced complexity, accelerated time to market, and helped SunsolveMD carve out a unique space in the crowded sun care category.

As SunsolveMD scales into new markets and product categories, BIG SKY PACKAGING remains a trusted partner, continuing to engineer packaging that not only protects— but performs.